feature Broaching in the 21st Century All Dressed Up with Places to Go Jack McGuinn, Senior Editor

Back around 2005-2010, the consistent as long as tools are properly provide additional impact on power most exciting things that were maintained.” savings, high efficiencies, and high- happening in broaching had lit- Michael Slovak, sales manager/ precision mechanical systems. Nachi’s tle to do with broaching. What machine tools division for Nachi primary developments include: Hard was happening — and continues to America Inc., adds additional evidence. broaching to minimize distortion after evolve today — was the emergence of on- “CNC, servo, and software technology heat treat. Also, Nachi green and hard the-edge CNC, software and servo drive continue to improve and skiving, including lathing, drilling and technology. Together, they practically taping, with (6) station automatic tool transformed a metalworking process as changer — is a multi-process alterna- old as water into a viable, alternative tive to broaching on lower part vol- consideration for producing high-vol- ume requirements. (And), the smaller ume part runs. Add to that enhanced GMS200 is currently moving into the tool coatings capabilities (which also introduction process.” just keep getting better) and broaching Given the above, broaching cer- found itself enjoying a bit of a relevance tainly remains a part of gear man- Renaissance. ufacturing. But, even with the But what about now — in 2018? Ten mentioned bells-and-whistles years is an eternity in today’s manufac- add-ons, can broaching crack turing operations, with new technol- manufacturing’s 21st century ogy breakthroughs occurring seem- lineup of Smart Manufacturing, ingly faster than one can keep up with. IoT, and Industry 4.1? Is broaching still in the equation in a “Customers now almost always meaningful way? ask for a communication link in Indeed it is — and then some. the broaching machine control “Yes, broaching remains one of the system, which they can utilize fastest methods of cutting production parts,” says Leon Agan, project engi- neer/estimator for American Broach & Machine, Inc. “High accuracy remains

Photo courtesy American Broach & Machine Co.)

[www.geartechnology.com] 26 GEAR TECHNOLOGY | May 2018 in whichever factory management sys- “The price of broach tools will be affected been any new applications happening tem they are using,” says Agan. “Most if tariffs remain on European tool steels. for broaching? Generally no, but those broaching machines use PLC rather than Broaching machines use large volumes of add-ons go a long way towards ensur- CNC control, and even those are outfit- structural steel, so there will probably be ing that broaching maintains its viability ted with a link for plant connection.” a significant impact on their pricing.” and retains its existing place in the gear Nachi’s Slovak points out that “While With the techy add-ons, have there machinery universe. the new buzz phrases define a specific characteristic, the technology to partici- pate in these areas has been available to machine makers for many years, and broaching is included. Providing critical data over a secure network to key indi- viduals, optimizing production func- tions, and increasing automation con- tinue to be improved and utilized.” Not to get too far off message, the thought occurs of how protracted steel tariffs on foreign steel might impact broaching’s world — especially tooling. “As with any change in such policy there is always potential for price impact and broaching must be reviewed on an ongoing basis,” says Slovak. As for American Broach’s Agan, see above answer — with this added proviso:

May 2018 | GEAR TECHNOLOGY 27 feature BROACHING IN THE 21ST CENTURY

“Most applications remain traditional, ‘techy add-ons’ can apply to any market but the amount of automation required that requires high annual volumes and for production cell integration has high capability.” Looking forward, he increased,” Agan says. “Customers want also states that “Electric vehicle compo- to eliminate broaching machine pits and nents may be the largest emerging new operator stands, and minimize operator application.” involvement. They ask for features such Given the fluids involved in broach- as onboard measurement of parts. Also, ing, and the maturity of the broaching we have come up with several designs to process, you would think broaching is a make changeover faster and easier.” particularly down-and-dirty process. But Slovak believes “Broaching with that’s not quite the case if proper steps

SPIRAL BEVEL GEAR CUTTING MACHINE HIGH PRECISION, GOOD RELIABILITY, GREAT VALUE

(Photo courtesy of Nachi America, Inc.)

are taken to alleviate the situation. American Broach’s Agan explains that “Normally, cutting fluid is splash- ing around freely inside a broaching machine. The process requires a flood of coolant, rather than a high-pressure blast. The current guarding designs do a good job of containing the cutting oil (normally water-soluble), and air blow- off stations can be added to reduce cool- ant carry-off. Dry broaching methods are being developed, but for now, most CNC Spiral Bevel Gear Cutting Machine customers are still using gallons of cut- ting oil. Siemens 840D Controller, utilizing five (5) synchronized axes “The typical oil or oil soluble cuttings LUREN designed easy to use, Microsoft Windows© based software fluids may not be known as producing a Precision cutting to 100 mm O.D., with maximum Module of M3 ‘clean process,’ says Slovak, “(but) steps Cup type milling cutter with HSK tool holder & 4,000 RPM Spindle can be taken to minimize or stop the Easy adjustment of contact pattern by point, click & drag escape of cutting fluids outside of the Also Available：LUREN’S LVG-100 Spiral Bevel Gear Grinding Machine machine being utilized. MQL (mini- mum-quantity lubrication), where avail- Our Gear Cutting Tools Hobs Shaper Cutters Master Gears able, is contributing to a much cleaner For over 20 years of manufacturing, Luren and more cost-effective process.” has been offering a wide variety of custom Back in 2010, what might be consid- and standard gear cutting tools using the ered “old-school” hydraulic machines highest quality materials and accuracy to ruled regarding large-component appli- ensure your longest possible tool life. cations. In 2018? Still very much in the Corporate Headquarters North American Headquarters game in a big way. Luren Precision Co., Ltd. Luren Precision Chicago Co., Ltd. “Hydraulic machines will always have a No.1-1, Li-Hsin 1st Road, 707 Remington Road, Suite 1, role — especially high tonnage long stroke Hsinchu City, Taiwan, 30078 Schaumburg, IL 60173, U.S.A. Phone : +886-3-578-6767 Phone : 1-847-882-1388 machines,” Agan affirms. “They have a Email : [email protected] Email : [email protected] fairly simple design and are very reliable. Website : www.luren.com.tw Website : lurenusa.com About half of the customer base considers

[www.geartechnology.com] 28 GEAR TECHNOLOGY | May 2018 an electro-mechanical machine for small- As mentioned, broaching is intended between sharpening; the number of runs- to-mid-range applications.” He further for high-volume production runs. So per-tool; and the cost of sharpening. explains that “Electro-mechanical usu- what goes into identifying the high-vol- American Broach can provide specific ally wins when floor space is an issue, ume break-even point that determines information when quoting a job to help or when a plant needs to minimize the whether broaching is more cost-effective a potential customer decide if broaching amount of hydraulic oil in use.” than other cutting technologies? offers the best value.” “Old-school” hydraulic machines still “Ten thousand pieces is still consid- Add to that, according to Slovak: rule in any application where part speci- ered to be very low volume in the broach- “Reviewing the part volume against ini- fication allowances and CapEx budgets ing industry,” says Agan. “Considerations tial CapEx costs; amortizing schedule; drive such a decision,” says Slovak. are: new vs. used machinery; initial tool- ongoing perishable tooling costs; reg- Is new machinery still a relevant part ing cost; the total length of cut expected ularly planned machine maintenance of the broaching industry? Or re-engi- neering/retrofitting existing machines? “New machines are about two-thirds of our machine sales,” says Agan. “Most of the time, we can offer our customer a completely rebuilt used machine as a Nachi America Inc. Introduces... lower-cost alternative. The frames of old machines last a long time, and with care- Nachi Tool America Inc. ful restoration of sliding surfaces and the addition of modern controls, we can Greenwood, Indiana facilities confidently offer the same warranty that we provide with a new model.” Manufacturing, Regrinding & Coating “New machinery is relevant based on for all Industries highly engineered part specifications and quality capability requirements,” Slovak says. “Complete rebuilding of BroachesBroaches •• CarbideCarbide DrillsDrills •• HobsHobs an existing machine can be an attrac- ShaperShaper CuttersCutters •• SkivingSkiving CuttersCutters tive, economical solution, (but) when the right frame is not available a new ShaveShave CuttersCutters •• FormingForming RacksRacks machine is recommended.” From the technological mindset of what have you done for me lately, have there been additional software, CNC, servo upgrades in this decade that have further enhanced broaching capabilities in a significant way? Slovak cites “Continued improve- ments in human machine interface capa- bility and programming can allow for improved and more efficient setting of processing requirements. The CNC, servo-operated machines continue to allow development in processing speeds, achieving faster machine cycle times.” As for Agan, he presents a somewhat less sanguine view. “Broaching does not benefit a whole lot from CNC advance- ments in the number of controlled axes, the ability to coordinate axes, or more sophisticated part programming software. We have a straight line application for the most part.” But also offers that “Many 717 Pushville Rd., Greenwood, IN 46143 control systems have become more open 317-535-0320 Gear Tools • 888-340-8665 Cutting Tools to industry standards and interoperable www.nachiamerica.com with motors from other brands.”

May 2018 | GEAR TECHNOLOGY 29 feature BROACHING IN THE 21ST CENTURY

costs; ongoing utility costs — as com- Types of Broaching pared to the alternative cutting technol- (Courtesy American Broach & Machine) ogies using the same factors.” • Pot (external spline or profile). A convenient load height for the opera- So broaching not only has a long part is pushed up through a circular tor, as no pit or operator platform is history; it would also appear to have array of surface broaches, resulting required. a strong future. The new wine in old in a gear or similar form on the out- • Vertical Pull-Down Broach. The bottles metaphor seems to apply here side circumference; high throughput part is placed in a fixture, and a in a meaningful way — or is it old wine with good surface finish. broach tool is pulled downward in new bottles? — (never can get that • Horizontal. A broach tool is pulled through it to produce an internal one straight). According to American horizontally through a part placed form. These machines are very rigid in a fixture or on a work horn. Broach’s Agan, “There has been a great and can produce cuts with tight tol- Commonly used for cutting key- erances and very good surface finish. increase in the number of customers ways and windows, but can also be The disadvantage is that the work seeking a hard broaching (a recent vin- used for internal splines with looser table is very high relative to the floor. tage) solution. We have been working tolerances. • Vertical Surface Broach. The part is with several to develop a process which • Vertical Table Up Broach. The part clamped in a fixture, and a set of flat is most effective for them.” is set in a fixture on a ram which broach tools on the ram slide move Nachi America’s Slovak’s outlook is carries it over and past a station- past and cut into the external sur- positive as well, but points out that there ary broach tool. The advantage is a face. This process can produce flat is much due diligence involved surfaces or complex forms, such as to keep it that way and to spline racks or turbine hub “fir tree” maintain market share. slots. “The markets are requir- • Twin-Cylinder Pull-Down Broach. This is a form of pull down broach ing broach builders to sup- which has a pair of cylinders ply finishing processes with (or linear actuators) mounted high speed, on a wide variety to the work table and stroking of parts, and lower volume downward into the base of the production runs. We have machine. The ends of the cylin- moved toward market demand der rods are bridged, so that they with CNC broach machines can carry the pull head. This (mass production ), com- system keeps the pull force pact hard broach machines, in line with the broaching small or large helical broach- axis, which eliminates canti- ing machines, and skiv- lever effect inherent in other systems. The pull lug is also ing (wide part variety, lower guided on ground posts, production) machines. We are maintaining a high degree of also able to offer integrated broaching accuracy. solutions with robotic (Nachi • Table Top Broach. This Robotic Systems) load/unload is another form of pull- automation for all machine types. down broach with a small Our broaching machines and footprint and compact skiving machines are solutions design. Instead of a ram for covering customer process slide, a pair of ball screws t re n d s .” on each side of the broach- ing axis moves the pull For more information lug. American Broach & American Broach & Machine Company Machine Company builds 575 South Mansfield this “TT” model, which Ypsilanti, Michigan 48197 has many of the same Phone: (734) 961-0300 high end features as larger Fax: (734) 961-9999 machines. Nachi America Inc. North American Headquarters (Machine Division) 46200 Twelve Mile Rd. Novi, MI 48377 For Related Articles Search Phone: (248) 835-5688 www.nachiamerica.com broaching at www.geartechnology.com Photo courtesy American Broach & Machine Co.

[www.geartechnology.com] 30 GEAR TECHNOLOGY | May 2018